Optimization of HSE in maintenance activities by integration of continuous improvement cycle and fuzzy multivariate approach: A gas refinery

Gas refineries have been continuously focusing on Health, Safety and Environment programs to improve maintenance activities. Several researches have studied on this area with different analysis methods. This study presents an integrated approach for optimization of factors contributing to the implementation of Health, Safety and Environment (HSE) in maintenance activities. HSE managers in each sector answered standard questionnaire whit respect to HES. The methodology is based on fuzzy data envelopment analysis (FDEA) and Deming's continuous improvement cycle. Also, this method is used to rank the relevant performance efficiencies in certain and uncertain conditions of each HSE sectors whit considering HSE in maintenance activities. It corresponds and integrates its registered HSE-MS with OHSAS 18001:2007 and ISO 14001:2004 to evaluate multiple inputs and outputs of over 36 subsidiary HSE divisions with parallel mission and objectives simultaneously. Also, it determines efficient target indices and could assure continuous improvement in the organization. This is the first study that introduces an integrated approach to improve HSE management programs in a gas refinery by a robust and continuous improvement approach.     

Performance assessment and optimization of HSE management systems with human error and ambiguity by an integrated fuzzy multivariate approach in a large conventional power plant manufacturer

This study presents an integrated approach performance assessment and optimization of integrated health safety environment (HSE) management system-based on fuzzy data envelopment analysis (FDEA) considering the possible human error and data vagueness in a conventional power plant manufacturer. In doing so, it corresponds and integrates its registered HSE-MS with OHSAS 18001:2007 and ISO 14001:2004 to evaluate multiple inputs and outputs of over 35 subsidiary HSE divisions with parallel mission and objectives simultaneously. The HSE divisions of each subsidiary are considered as decision making units (DMUs). Not only doing this refutable method rank their relevant performance efficiencies in certain and uncertain conditions, but also it determines efficient target indices for each DMU, and could assure continuous improvement in the organization. This would help managers to identify the areas of strengths and weaknesses in their HSE management system and set improvement target plan for the related HSE management system. In this model based on Deming’s continuous improvement cycle, managers are also able to evaluate the prevailing strengths and weaknesses and target their improvement strategies at the relevant stages of the cycle.     

A new approach for layout optimization in maintenance workshops with safety factors: The case of a gas transmission unit

In this study, an Integrated Simulation-Data Envelopment Analysis (DEA) approach is presented for optimum facility layout of maintenance workshop in a gas transmission unit. The process of repair of incoming parts includes various operations on different facilities. The layout problem in this system involves determining the optimum location of all maintenance shop facilities. Layout optimization plays a crucial role in this type of problems in terms of increasing the efficiency of main production line. Standard types of layouts including U, S, W, Z and straight lines are considered. First, the maintenance workshop is modeled with discrete-event-simulation. Time in system, average waiting time, average machine utilization, average availability of facilities, average queue length of facilities (AL) and average operator utilization are obtained from simulation as key performance indicators (KPIs) of DEA. Also, safety index and number of operators are considered as other KPIs. Finally, a unified non-radial Data Envelopment Analysis (DEA) is presented with respect to the stated KPIs to rank all layouts alternatives and to identify the best configuration. Principle Component Analysis (PCA) is used to validate and verify the results. Previous studies do not consider safety factor in layout design problems. This is the first study that presents an integrated approach for identification of optimum layout in a maintenance workshop of gas transmission unit by incorporating safety and conventional factors.     

Modeling and optimizing efficiency gap between managers and operators in integrated resilient systems: The case of a petrochemical plant

The reliability issue in complex industrial systems such as oil, gas, petrochemical companies, nuclear and aviation industries has been of great importance. Resilience engineering (RE) is a new attitude toward the improvement of safety and reliability in the stated systems. One of the challenges a resilient system might face is the gap between work as imagined by managers and work as actually done by operators. This study will introduce a new framework named integrated resilience engineering (IRE) as a result of developing the concept of RE. The data used in this research have been obtained by means of questionnaire from a petrochemical company. Thereafter, the efficiency of operators and managers are calculated in RE and IRE frameworks through data envelopment analysis (DEA) approach. Then, the gaps between managers and operators are analyzed in two frameworks. The results are indicative of a significant growth in the number of efficient operators and managers in IRE framework compared to RE framework. Besides, the efficiency mean of managers and operators in IRE framework has experienced the growth of 1.8% and 5% compared to RE framework, respectively. The efficiency gap between managers and operators in IRE framework has also enjoyed the improvement of 88% compared to RE framework. Generally, it can be said that the suggested items of this research has led to the betterment of managers and operators’ efficiency and of the efficiency gap between them. Therefore, these items can improve the resilience and safety of complex systems. The results of Spearman test show that there is a strong direct correlation between the DEA results in two frameworks. This is the first study that examines the efficiency gap between operators and managers based on the RE principles and by means of DEA approach.     

An adaptive neural network algorithm for assessment and improvement of job satisfaction with respect to HSE and ergonomics program: The case of a gas refinery

Researchers have been continuously trying to improve human performance with respect to Health, Safety and Environment (HSE) and ergonomics (hence HSEE). This study proposes an adaptive neural network (ANN) algorithm for measuring and improving job satisfaction among operators with respect to HSEE in a gas refinery. To achieve the objectives of this study, standard questionnaires with respect to HSEE are completed by operators. The average results for each category of HSEE are used as inputs and job satisfaction is used as output for the ANN algorithm. Moreover, ANN is used to rank operators performance with respect to HSEE and job satisfaction. Finally, Normal probability technique is used to identify outlier operators. Moreover, operators with inadequate job satisfaction with respect to HSEE are identified. This would help managers to see if operators are satisfied with their jobs in the context of HSEE. This is the first study that introduces an integrated ANN algorithm for assessment and improvement of human job satisfaction with respect to HSEE program in complex systems.     

基于改进JHA铜冶炼维修作业风险辨识与信息化应用

基于能量意外释放论,提出改进的JHA风险辨识方法。在按设备结构划分维修作业后,不划分作业步骤,而是根据风险来源进行辨识,实现了辨识的实用性和系统全面性。基于辨识结果,建立信息化维修作业风险信息数据库,并作为《检修项目指令书》安全措施的信息支撑。实践表明,改进的JHA辨识方法是有效的,信息化应用改变了经验式的《检修项目指令书》,提高了风险管控的有效性。     

基于有界数据包络分析(DEA)模型的应急避难场所效率评价

应用数据包络分析(DEA)方法,针对应急避难场所规划建设和运营维护两种情况,分别建立以建设成本和运营成本为输入指标,以服务性、可达性、安全性为输出指标的效率评价指标体系,并选择有界DEA模型,分层次对应急避难场所的投入产出效率进行评价。实证案例表明,临时和中长期避难场所比短期避难场所更容易获得较高的DEA效率;位于区域内部、交通便利的应急避难场所DEA效率较高;提高应急避难场所的综合利用水平,更有利于提高其DEA效率。     

Assessment and improvement of integrated HSE and macro-ergonomics factors by fuzzy cognitive maps: The case of a large gas refinery

This study analyzes and assesses the integrated health, safety, environment (HSE) and ergonomics (HSEE) factors by fuzzy cognitive maps (FCM) approach. This is achieved through integrating ergonomic and macro-ergonomic as well as occupational health and safety arrangements in an integrated modeling for assessment of their multi-faceted impact on workers' productivity, injury rate and satisfaction. This paper uses FCM to assess the direct and indirect effects of HSEE factors on system performance indicators. The results of FCM are used to develop leading indicators useful for proactive management of productivity, injury rate, and job satisfaction. The result of a comprehensive survey of 37 experts in control rooms and maintenance activities in a large gas refinery is used to show the applicability and usefulness of FCM approach. Moreover, FCM results are used to determine the causal structure of HSEE factors and system performance indicators. It is concluded that macro-ergonomics factors such as instructions and education, familiarity with organization's rules, and proper communications most contribute to improve workers' safety, satisfaction, and productivity.     

Developing a risk-based maintenance model for a Natural Gas Regulating and Metering Station using Bayesian Network

During the last decades, the vital role of maintenance activities in industries including natural gas distribution system has cleared up progressively. High costs may induce to reduced maintenance and, in turn, lead to a lower availability and high risk of undesired events. Therefore, a probabilistic model, based on an acceptable level of risk, is required to avoid under and over estimation of maintenance time interval. This paper presents an advanced Risk-based Maintenance (RBM) methodology to optimize maintenance time schedule. Bayesian Network (BN) is applied to model the risk and the associated uncertainty. The developed method can assist the asset managers to work out the exact maintenance time for each component according to the risk level. To demonstrate and discuss the applicability of the methodology, a case study of Natural Gas Reduction and Measuring Station in Italy is considered. Results prove that the most critical components are the calculator and pilots, while the most reliable one is the odorization. Furthermore, the pressure and temperature gauge (PTG), the remote control system (RCS) and the meter are predicted as the components that require less time to transit from minor risk to catastrophic risk.     

基于DEA的海外石油钻探项目HSE管理能力评价

基于课题组对大庆工程钻探公司349份有效问卷的样本数据,采用因子分析法对各指标进行筛选和验证;构建了海外石油钻探项目HSE管理能力评级指标体系和海外石油钻探项目HSE管理能力评价模型;采用DEA法分别对三个维度下不同地区的石油钻探项目HSE管理能力进行了分析,并运用DEA交叉法对不同项目的 HSE管理能力进行了比较分析。研究表明:海外石油钻探项目HSE管理能力中健康管理能力最强,环境管理能力最弱;海外不同国别的项目HSE管理能力差异明显。最后,提出了提升海外石油钻探项目HSE管理能力的对策建议。     

The impact of job security,satisfaction and stress on performance assessment and optimization of generation companies

In this study, performances of Iranian thermal power plants have been assessed with respect to human factors such as job stress, satisfaction and security through data envelopment analysis (DEA). In the first step performance of power plants (DMUs) have been evaluated considering traditional production factors including installed capacity, internal consumption and fuel consumption as inputs and gross production as output (model 1). In the next step, model 1 is expanded to include three above mentioned human factors (model 2). Power plants have been ranked based on their relative efficiency scores in both models. Pearson and Spearman correlation coefficients between relative efficiency scores and rankings of power plants in two models have been calculated. The results show that efficiency scores and rankings of power plants in two models are quite different indicating that mentioned human factors have direct impact on overall performance of generation companies and that if we were to use just traditional factors it would not reflect the optimum efficiency of the DMUs. Finally, job security has been found as the most effective human factor in Iranian power plants. This is the first study that presents an integrated approach for assessment of electric power plants considering job stress, security and satisfaction. And it is shown that these human factors play important role in overall performance of generation companies.     

Identification of managerial shaping factors in a petrochemical plant by resilience engineering and data envelopment analysis

Resilience engineering (RE) is a novel approach that is capable of controlling and limiting incidents and accidents. This study identifies managerial shaping factors in a petrochemical plant by RE and data envelopment analysis (DEA). To do this, a standard questionnaire containing resilient factors is completed by managers of a petrochemical plant. Then, the best DEA model is selected based on average efficiency and statistical test. In addition, sensitivity analysis are performed to identify the most important shaping factors. Reporting culture, management commitment, and preparedness are identified as the most important factors in this paper, respectively. Finally, the proposed model is validated and verified through statistical experiment. The proposed approach would help managers to have a comprehensive understanding of the plant with respect to the RE. To the best of our knowledge this is the first paper that examines resilient shaping factors in a petrochemical plant with respect to management and organization by DEA.     

HAZOP分析中LOPA的应用研究

通过分析危险与可操作性研究(HAZOP)方法的不足和保护层分析(LOPA)方法的功能,提出将LOPA融入HAZOP分析中,能进一步提高HAZOP的事故预防能力和丰富HAZOP的分析结果。介绍LOPA基本方法,阐述LOPA融入HAZOP的机理、衔接关系及分析步骤,并通过一个化工工艺流程危险性分析实例说明LOPA的作用及如何将LOPA融入HAZOP分析中。结果表明:在HAZOP分析中融入LOPA方法,能实现对现有保护措施的可靠性进行量化评估,确定其消除或降低风险的能力,从而寻求是否需要附加减少风险的安全保护措施。     

The digital representation of safety systems at “Seveso” plants and its potential for improving risk management

At Seveso plants, duty holders must have a complex system for assessing and managing risks. The pillars of this system are the safety report and the safety management system, with a number of underlying documents. The strength of the system is the high standardization of these documents. Regulations, standard codes and guidelines define content, structure and formats. The weakness is the high complexity. Managers and workers perceive documents as difficult to understand and far from actual operations. Major threats for the credibility of documents (and therefore for the safety systems) come from the continuous organizational and technical changes, which in a short time can make most documents obsolete; as well as by near misses, which continuously show the holes in safety systems. A big effort is required to follow up the plant changes and the near misses. In order to help safety managers, a new software has been developed. At Seveso plants, it has been possible build an integrated digital representation, because all documents are perfectly structured. This representation may be used both for updating the relevant documents after a change and to improve documents after a near miss or an accident. In this way, safety documents are always up to date and trustworthy and the huge knowledge, which is usually hidden inside safety documents, is clearly revealed and revived. The approach is basically “knowledge based” and the intention is to provide safety managers with an easy and simple tool. IRISonLine is a software that has been developed by ISPESL to provide safety managers of “Seveso” establishments with a tool for improving the management of change and of near misses.     

Study and application of Reliability-centered Maintenance considering Radical Maintenance

Radical Maintenance (RM) takes the root causes of failures as executive objects to make maintenance decisions. A Root Cause Analysis (RCA) is carried out on the function failure of equipment to perform RM and to create a maintenance plan using the combined methods of Failure Mode, Effects and Criticality Analysis (FMECA), and Fault Tree Analysis (FTA). Evaluation criteria and matrixes of criticality are used to evaluate the criticality level of failure modes. Moreover, Minimum Cut Sets (MCS) and importance calculation are applied to analyze the fault tree quantitatively. Based on our research, the concept and the analysis process of Reliability-centered Maintenance (RCM) considering RM are proposed and then applied to an actual engineering project in the petrochemical industry. The results of the application are presented through a maintenance strategy based on the project analysis by establishing the evaluation criteria and matrixes of criticality for petrochemical rotating machines and a fault tree of compressor vibrations. The direct causes of the induction of vibration faults in rotating machinery are classified according to the fault mechanism and frequency domain features in this paper. The research shows that using RM in the traditional RCM can help assign maintenance resources rationally and improve the quality of maintenance strategies.     

中国石油集团公司HSE管理体系运行模式的研究

从1991年国际石油工程协会把健康安全与环境(简称HSE)作为一个完整概念提出以来,各国石油公司都进行了积极探索与实践,并逐步发展成国际石油届开展合作业务的基本运行规则.中国石油天然气集团公司结合企业生产实际和传统管理方法,在HSE管理体系探索、实践中,发展了一整套既符合中国石油企业管理实际的情况,又满足与国际接轨要求的HSE运行模式,对企业实施HSE管理体系有很好指导意义.     

Performance evaluation of process industries resilience: Risk-based with a network approach

Risk management can be defined as coordinated activities to conduct and control an organization with consideration of risk. Recently, risk management strategies have been developed to change the approach to hazards and risks. Resilience as a safety management theory considers the technical and social aspects of systems simultaneously. Resilience in process industries, as a socio-technical system, has four aspects of early detection, error-tolerant design, flexibility, and recoverability. Meanwhile, process industries' resilience has three phases: avoidance, survival, and recovery, determining the transition between normal state, process upset event, and catastrophic event. There may be various technical and social failures such as regulatory and human or organizational items that can lead to upset or catastrophic events. In the avoidance phase, the upset event is predicted, and thus, the system remains in a normal state. For the survival phase, the system state is assumed to be an upset process event, and the system tries to survive through the unhealthy process conditions or remains in the same state, probably with low performance. In the recovery phase, the system is supposed to be catastrophic, and the emergency barriers are prioritized to show the severity of the consequences and response time, leading to a resumption of a normal state. Therefore, a resilience-based network can be designed for process industries to show its inherent dynamic transition in nature. In this study, network data envelopment analysis (DEA), as a mathematical model, is used to evaluate the relative efficiency of the process industries regarding a network transition approach based on the system's internal structure. First, a resilience-based network is designed to consist of three states of normal, upset, and catastrophic events. Then, the efficiency of each industrial department, which is defined as decision-making units (DMUs), is evaluated using network DEA. As a case study, a refinery that is considered a critical process industry is assessed. Using the proposed model shows the efficient and inefficient DMUs in each of three states of normal, upset, and catastrophic events of the process and the projection onto efficient frontiers. Besides calculating the network efficiency, the performance of each state is extracted to precisely differentiate between DMUs. The results of this study, which is one of the fewest cases in the area of performance evaluation of process industries with a network approach, indicated a robust viewpoint for monitoring and assessment of risks.     

On risk-based maintenance: A comprehensive review of three approaches to track the impact of consequence modelling for predicting maintenance actions

Since gas plants are progressively increasing near urban areas, a comprehensive tool to plan maintenance and reduce the risk arising from their operations is required. To this end, a comparison of three Risk-Based Maintenance methodologies able to point out maintenance priorities for the most critical components, is presented in this paper. Moreover, while the literature is mostly focused on probabilistic analysis, a particular attention is directed towards consequence analysis throughout this study. The first developed technique is characterized by a Hierarchical Bayesian Network to perform the occurrence analysis and a Failure Modes, Effects and Criticality Analysis to assess the magnitude of the adverse outcomes. The second approach is a Quantitative Risk Analysis carried out via a software named Safeti. Finally, another software called Synergi Plant is adopted for the third methodology, which provides a Risk-Based Inspection plan, through a semiquantitative risk analysis. The proposed study can assist asset manager in adopting the most appropriate methodology to their context, while highlighting priority components. To demonstrate the applicability of the approaches and compare their rankings, a Natural Gas Regulating and Measuring Station is considered as case study. The results showed that the most suited method strongly depends on the available data.     

谈职业健康安全管理体系审核的有效性

笔者从审核人日、抽样的合理性、审核员能力、审核过程的有效性等4个方面讨论了职业健康安全管理体系(OHSMS)审核的有效性。从要素的角度,介绍国家标准GB/T28001—2001中“对危险源辨识,风险评价和风险控制的策划”,“法律法规及其他要求”,“职业健康安全管理方案”,“结构和职责”,“运行控制”,“绩效测量与监测”,“事故事件,不符合,纠正与预防措施”等7个要素审核过程的有效性。可为认可认证机构判断OHSMS审核的有效性提供一定的参考。